Bodysuit with integrated lining structure and method of manufacture

ABSTRACT

In some embodiments, a bodysuit includes an outer shell with front and rear panel and a first inner lining with front and rear panels. Each of the front and rear panels of the first inner lining extends from above a waistline of the bodysuit to a seam at a respective side of a crotch region. The bodysuit may include a second inner lining attached to the front and rear panels of the first inner lining at first and second seams, the first and second seams located at first and second sides of the crotch region. The bodysuit also may include a third inner lining positioned on top of and attached to the second inner lining. Attachment of the first inner lining to the second inner lining and the second inner lining to the third inner lining may be accomplished via inner seams not visible on an exterior of the bodysuit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. U.S. 62/510,252, entitled “BODYSUIT WITHINTEGRATED LINING STRUCTURE AND METHOD OF MANUFACTURE” and filed May 23,2017, the contents of which are incorporated herein by reference in itsentirety.

FIELD

The disclosed embodiments are generally directed to bodysuits, and moreparticularly to bodysuits with integrated lining structures and methodsof manufacture.

BACKGROUND

Bodysuits are articles of clothing that are worn by female and males,such as dancers, swimmers, cyclists, yogis and gymnasts. Typically, thebodysuit covers at least the torso, portions of the back, the buttocksand the crotch of the wearer, with openings for the neck, arms, andlegs. In some instances, the bodysuit may include sleeves and/or legs.

SUMMARY

In one embodiment, a bodysuit includes an outer shell having a frontpanel and a rear panel, a first inner lining attached to the outershell, the first inner lining having a front panel and a rear panel, thefront panel of the first inner lining extending from above a waistlineof the outer shell front panel to a first seam and the rear panel of thefirst inner lining extending from above a waistline of the outer shellrear panel to a second seam, wherein the first seam is located at afirst side of a crotch region of the bodysuit and the second seam islocated at a second, opposite side of the crotch region of the bodysuit,and a second inner lining attached to the first inner lining at thefirst and second seams.

In another embodiment, a method of constructing a bodysuit having anouter shell with front and rear panels is disclosed. The method includesattaching a front panel of a first inner lining to a front panel of anouter shell of the bodysuit and attaching a rear panel of the firstinner lining to a rear panel of the outer shell, wherein the front panelof the first inner lining extends from a portion above a waistline ofthe outer shell to a first seam and the rear panel of the first innerlining extends from a portion above the waistline of the outer shell toa second seam, the first seam defining a first edge of a crotch regionof the bodysuit and the second seam defining a second edge of the crotchregion, and attaching a second inner lining to the front and rear panelsof the first inner lining at the first and second seams.

It should be appreciated that the foregoing concepts, and additionalconcepts discussed below, may be arranged in any suitable combination,as the present disclosure is not limited in this respect.

The foregoing and other aspects, embodiments, and features of thepresent teachings can be more fully understood from the followingdescription in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In thedrawings, each identical or nearly identical component that isillustrated in various figures is represented by a like numeral. Forpurposes of clarity, not every component may be labeled in everydrawing. In the drawings:

FIG. 1 is a front view of a bodysuit according to one embodiment;

FIG. 2 is a rear view of the bodysuit of FIG. 1;

FIG. 3 is a front view of a bodysuit according to another embodiment;

FIG. 4 is an interior view of a bodysuit prior to final assembly, withfront and rear panels attached only in a crotch region of the bodysuit;

FIG. 5 is a front view of an interior of a bodysuit according to oneembodiment;

FIG. 6 is a rear view of the bodysuit of FIG. 5;

FIG. 7 illustrates an outer shell front panel and a first inner liningfront panel of a bodysuit according to some embodiments;

FIG. 8 illustrates an outer shell rear panel and a first inner liningrear panel of the bodysuit of FIG. 7;

FIG. 9 is a side view of the bodysuit of FIG. 5;

FIG. 10 is an top view of the interior of the bodysuit of FIG. 1;

FIG. 11 is top view of a second inner lining of a bodysuit according tosome embodiments;

FIG. 12 shows a third inner lining of a bodysuit according to someembodiments;

FIGS. 13-15 illustrate attachment of first, second and third innerlinings of a bodysuit;

FIGS. 16A and 16B illustrate front and rear fragmentary views of abodysuit according to one embodiment;

FIGS. 17A and 17B illustrate construction of a leg opening bend backaccording to one embodiment;

FIGS. 18A and 18B illustrate attachment of second and third innerlinings to the leg opening bend back of FIGS. 17A and 17B;

FIGS. 19A and 19B are enlarged cross sectional views of second and thirdinner linings attached to a leg opening bend back according to someembodiments;

FIG. 20 is a cross sectional side view of a crotch region of a bodysuit;and

FIG. 21 is a table listing types of fabrics and fabric treatments.

DETAILED DESCRIPTION

Bodysuits are articles of clothing that may be worn to be form fittingand highlight a wearer's muscle definition and skeletal alignment, andto allow for unencumbered movement and comfort. For purposes herein, abodysuit may include a leotard, a unitard, a swimsuit, a biketard, orsimilar garments. Bodysuits may be used in various athletic activities,such as for dance, yoga, pilates, running, swimming, and gymnastics.Bodysuits are typically worn without any additional garments over orunderneath the bodysuit. In some embodiments, the bodysuit can cover thebody like a second skin and provide modesty. Typically, a bodysuitcovers at least the torso, a portion of the back, the buttocks and thecrotch of the wearer, and has openings for the neck, arms and legs.Bodysuits also may include one or more sleeves of varying lengths and/orone or more pant legs of varying lengths.

Typically, a bodysuit includes an outer layer made of any one of avariety of synthetic and non-synthetic materials (e.g., nylon, polyesterand cotton) with fibers (e.g., spandex, lycra, rubber or elastane) thatallow the outer layer to stretch to varying degrees. The outer layer istypically constructed of front and back panels that are secured to oneanother on each side via a seam that may be stitched, welded or bonded.The front and back panels also may be secured to one another via asingle seam that is stitched, welded or bonded in or adjacent to thecrotch region. In some embodiments, the crotch region of the outer shellmay be formed via at least a portion of the front panel and/or at leasta portion of the rear panel. For example, a portion of the front panelmay extend from the front of the garment, through the crotch region, andbe attached to the rear panel via a seam at a rear of the crotch region.In some embodiments, the leg, arm and neck openings may be finished withdecorative stitching, binding or elastics, and/or straps.

For purposes herein, the crotch region may include a portion of thebodysuit, such as a portion of the outer shell or one of the innerlinings, that extends between the leg openings and is adjacent to acrotch of the wearer when the bodysuit is being worn. For example, forfemale wearers, the crotch region may be a portion of the bodysuit thatis positionable over the wearer's vulva, pudendal cleft and mons pubis.In some embodiments, the crotch region is located between the leg holesof the bodysuit and extends upwardly toward the front of the bodysuitand rearwardly toward the rear of the bodysuit. In some embodiments, thecrotch region may be substantially hourglass in shape.

A bodysuit also may include an inner lining that covers, supports and/orprotects the whole torso or portions thereof. An inner lining typicallyincludes a single layer that is attached to the uppermost edges of thefront of the outer shell, such as from the neckline, and laterallyconnected to the side seam(s). The inner lining also may be connected tothe leg openings and reward under the crotch and towards the buttocks,where the inner lining is stitched to the seam at the rear end of thecrotch region. The lining may be made of a material with a similarstretch to that of the outer shell. Typically, bodysuits do not have alining attached to the rear of the bodysuit, unless there is a flaw inthe outer layer.

The female body from time to time excretes or can excrete bodily fluids,like vaginal discharge, menstrual flow and/or urine. While wearing atraditional bodysuit, the wearer may experience a variety of anxietiesand embarrassments from visible undergarments, sanitary napkins, tamponstrings and/or incontinence diapers. For example, because bodysuits aretypically form fitting, they are not discrete and may highlight theadditional undergarment and/or other sanitary product worn under thebodysuit. The additional undergarment and/or sanitary product also mayadd bulk and not be the same shape as the bodysuit or the wearer, thussignaling to the public that the wearer is protecting against thepossibility of excreting fluids.

Additionally, because excretions may occur at any unforeseen time, thewearer of the bodysuit may not be prepared and therefore may have anaccident. Wetness and/or blood may become visible on the outer layer(s)of the traditional bodysuit. The wearer also may wet or bleed throughthe bodysuit and any undergarment and/or sanitary product used tocontrol excretions. Such visible excretions may cause embarrassmentand/or undue distress to the wearer.

The inventors have recognized that advantages may be realized byproviding a bodysuit with one or more inner linings that are capable ofabsorbing and/or blocking the permeation of excretions without the useof an undergarment, overgarment or other sanitary product. For example,in some embodiments, the inner layers may reduce or even eliminate theneed for the wearer to use an undergarment or other sanitary product toprotect against menstruation, incontinence, or other female excretion.The inventors have further recognized that advantages may be realized ifsuch bodysuits are not distinguishable from typical bodysuits such thatthe wearer may not be identified as someone protecting againstincontinence, menstrual flow or other menstrual discharge. For example,in some embodiments, the bodysuit does not include visible seams in acrotch region of the outer shell where the one or more protective innerlinings may be present and attached to one another. As will beappreciated, the inner seams of the inner linings also may be located atother portions of the bodysuit, such as near the waist of the bodysuit,the inner seams not being visible near the waist of the outer shell.

To that end, embodiments disclosed herein include a bodysuit with anouter shell and one or more inner linings arranged to absorb and/orblock the permeation of excretions, the one or more inner linings notbeing visible from the exterior of the bodysuit. In some embodiments,the bodysuit includes an outer shell with front and rear panels. Thebodysuit also may include a first inner lining that has front and rearpanels, each of the panels of the first inner lining extending fromabove a waistline of the outer shell to a seam that may be at a first orsecond end of the crotch region. For example, the front panel of thefirst inner lining may extend all the way from the neckline of thebodysuit to a seam defining the front end of the crotch region. In suchembodiments, the first inner lining may be attached to the outer shellonly at the neckline and at one or more seams on a side of the bodysuit.

The bodysuit also may include a second inner lining that extends fromthe seam at the front of the crotch region to the seam at the rear ofthe crotch region. The second inner lining may be formed in the shape ofthe crotch region, such as having a substantially hourglass shape. Forexample, the second inner lining may be wider at the top and bottom thanin a central region. In some embodiments, the second inner lining isattached to the first inner lining at the seams at the front and rearedges of the crotch region. The bodysuit also may include a third innerlining that is placed on top of and is attachable to the second innerlining. In some embodiments, the third inner lining may have the sameshape as the second inner lining, and crotch region, but be smaller thanthe second inner lining. In some embodiments, by having a third liningthat is smaller than the second lining, fluids absorbed by the thirdlining may not be transferred to the outer shell (e.g., via the secondlining). In these embodiments, attachment between the second and firstinner linings and between the second and third inner linings may beaccomplished via inner seams that are not attached to the outer shell.In some embodiments, the third inner lining may include one or morelayers.

In these embodiments, each of the first, second and third inner liningsmay have a body contacting surface. In some embodiments, one or more ofthe inner linings may be arranged to absorb and/or wick fluids. In someembodiments, at least one of the inner linings acts as a barrier layerthat may minimize or prevent excretions from passing through to theouter shell. In some embodiments, the barrier layer may be stainreleasing so that the bodysuit is not permanently damaged during anaccident. In some embodiments, the layers may be formed of a stretchablematerial.

Turning now to the figures, FIGS. 1 and 2 show a bodysuit 100 accordingto embodiments of the present disclosure. As shown in these views, thebodysuit may have an outer shell with a front panel 102 a and a rearpanel 102 b. In some embodiments, the front and rear panels 102 a, 102 bare secured to one another via seams 104 located at opposite sides ofthe bodysuit 100, and via a rear outer seam 105 located adjacent to thecrotch region of the bodysuit. As will be appreciated in view of theabove, at least a portion of the front panel 102 a may form the crotchregion of the outer shell of the bodysuit. The front and rear panels 102a, 102 b also may be secured to one another along the top edge of theneckline 107 a, 107 b. In some embodiments, the rear outer seam 105 isnot visible in the inside of the bodysuit. As will be appreciated, sucha seam 105 may be obstructed by the one or more inner linings inside thebodysuit 100. As shown in FIGS. 1 and 2, other than then rear outer seam105, neither the front or rear panels 102 a, 102 b of the outer shellinclude seams visible on the outside of the garment, such as in thecrotch region, where one or more inner linings are attached to oneanother.

As will be appreciated, the outer shell of the bodysuit may have anysuitable configuration. For example, as shown in FIGS. 1 and 2, thebodysuit may have sleeves. In other embodiments, as shown in FIG. 3, thebodysuit also may be sleeveless. In some embodiments, the bodysuit maycover the legs, or at least a portion of the legs. As will beappreciated, in such embodiments, the one or more inner linings may beadjusted in size to accommodate the size and shape of the outer shell.

As shown in FIGS. 4-6, in some embodiments, the bodysuit may include twoor more inner linings. As will be described, the inner linings may beattached to one another and to the outer shell. In some embodiments, theinner linings may have different protective characteristics, such as forabsorbing, wicking, and/or blocking transmission of fluids.

In some embodiments, as shown in FIGS. 4-10 and 13, the bodysuitincludes a first inner lining having a front panel 106 a and a rearpanel 106 b. In some embodiments, the first inner lining may extend fromabove a waistline of the respective panel of the outer shell to a edgeof the crotch region 111. In this regard, the first inner lining may bearranged to not extend into the crotch region of the bodysuit.

As shown in FIGS. 4-6, in some embodiments, the crotch region may bedefined by a front seam 108 a at a front edge of the crotch region and arear seam 108 b at a rear edge of the crotch region. As will bedescribed, the first and second inner linings 106 a, 106 b, 110 may bejoined to one another via the front and rear seams 108 a, 108 b. As willbe appreciated from the above, the front and rear seams 108 a, 108 b maybe visible from the interior of the bodysuit but not visible on theexterior of the bodysuit.

As shown in FIG. 7, a length L1 of the front panel 102 a of the outershell may be longer than a length L2 of the front panel 106 a of thefirst inner lining of the bodysuit. In such embodiments, the front panelof the first inner lining may end at or above a crotch region of thebodysuit. As shown in FIG. 8, and similar to the front panels, a lengthL3 of the rear panel 102 b of the outer shell may be longer than alength L4 of the rear panel 106 b of the first inner lining in someembodiments.

As shown in FIGS. 7 and 8, the first inner lining may be formed in ashape similar to that of the outer shell. For example, the front andrear panels of the first inner lining have similarly shaped neckopenings and silhouettes. As shown in these views, the front and rearpanels 106 a, 106 b of the first inner lining need not include each ofthe features of the front and rear panels 102 a, 102 b of the outershell. For example, as shown in these views, the front and rear panels106 a, 106 b of the first inner lining do not have sleeve portions.

As will be appreciated, the length L1 of the front panel 102 a of theouter shell need not be the same as the length L3 of the rear panel ofthe outer shell. In a similar fashion, the length L2 of the front panel106 a of the first inner lining may be different than the length L4 ofthe rear panel 106 b of the first inner lining. As will be furtherappreciated, the front and rear panels 106 a, 106 b of the first innerlining may be formed of the same material or may be formed of differentmaterials. For example, the front panel of the inner lining may beformed of a material that is arranged to wick fluids, while the rearpanel of the inner lining may be formed of a stretchable material withno protective features.

In some embodiments, as shown in FIG. 9, the front and rear panels 106a, 106 b of the first inner lining are secured to the front and rearpanels 102 a, 102 b of the outer shell at seams 104 located on oppositesides of the bodysuit. As shown in FIGS. 4-6, The first inner lining 102a, 102 b also may be secured at a neckline 107 a of a front of thebodysuit and a neckline 107 b of the rear of the bodysuit.

As shown in FIGS. 4-6, 9-10 and 14, the bodysuit 100 also includes asecond inner lining 110 positioned in the crotch region of the bodysuit.In some embodiments, as shown in these views, the second inner lining110 is attached to the front panel 106 a of the first inner lining atthe front seam 108 a and to the rear panel 106 b of the first innerlining at the rear seam 108 b. In such embodiments, the second inner mayextend along the crotch region 111 of the bodysuit.

As shown in FIGS. 4 and 10-11, the second inner lining 110 may have asubstantially hourglass shape, with front and rear portions of thesecond inner lining 110 being wider than a central portion. For purposesherein, the front portion of the second inner lining is the portion ofthe second inner lining that is positioned towards the front of thebodysuit when the bodysuit is worn by the user, and the rear portion isthe portion positioned towards the rear of the bodysuit. As shown inthese views, the front portion of the second inner lining 110 need notbe the same size (e.g., the same width) as the rear portion of thesecond inner lining 110. For example, as shown in FIG. 11, a rearportion of the second inner lining 110 may be wider than the frontportion. In some embodiments, the second inner lining may be the samesize as the crotch region of the outer shell. In other embodiments, thesecond inner lining may be larger than the crotch region. As will beappreciated, the shape and size of the second inner lining may varybased on the shape and size of the crotch region of the outer shell.

As also shown in FIGS. 4-6 and 9-10, the bodysuit also may include athird inner lining 112. As with the second inner lining, the third innerlining 112 is also arranged to be positioned in the crotch region of thebodysuit. As shown in FIG. 10, the third inner lining 112 is attached tothe second inner lining via front 114 a and rear 114 b seams. In someembodiments, the second inner lining is flatlocked on top of the firstinner lining at the front and rear seams 108 a, 108 b. As with otherembodiments, the front and rear seams 114 a, 114 b are positioned towarda front and rear of the garment, respectively, when the garment is wornby the wearer. In some embodiments, the second and third inner linings110, 112 may be attached (see stitching 115 in FIG. 10) on top of a legopening 116 bend back.

In some embodiments, as shown in FIGS. 4-6, and 9-10, the third innerlining is smaller than the second inner lining. In some embodiments, byhaving the third inner lining be smaller than the second inner lining,fluids absorbed by the third inner lining may not be transferred to theouter shell. In such embodiments, the front seam 108 a attaching thesecond inner lining 110 to the first inner lining 106 a is spaced fromthe front seam 114 a attaching the third inner lining 112 to the secondinner lining 110. In a similar fashion, the rear seam 108 b attachingthe second inner lining 110 to the first inner lining 106 a may bespaced from the rear seam 114 b attaching the third inner lining 112 tothe second inner lining 110. As will be appreciated, the respectivefront seams 108 a, 114 a and rear seams 108 b, 114 b may belongitudinally spaced from one another.

As shown in FIG. 15, the front seams 108 a, 114 a may be spaced adistance D1 of at least about 0.25 inches from one another. For example,the seams 108 a, 114 a may be spaced a distance D1 of between about 0.25inches and about 1 inch. In a similar fashion, the rear seams 108 b, 114b may be spaced a distance D2 of at least about 0.25 inches from oneanother. For example, the seams 108 b, 114 b may be spaced a distance D2of between about 0.25 inches and about 1 inch. As will be appreciated,the distance D1 between the first seams 108 a, 114 a and the distance D2between the rear seams 108 b, 114 b may be the same in some embodiments.For example, the distances D1, D2 may be about 0.375 inches. In otherembodiments, the distances D1, D2 may be different from one another.

As also shown in FIG. 15, a side of the third inner lining 112 may bespaced from a side of the second inner lining 110. For example, in someembodiments, the side of the third inner lining may be spaced a distanceD3 of at least about 0.125 inches. For example, the side of the thirdlining may be spaced a distance D3 of between about 0.125 inches and0.375 inches. For example, in some embodiments, the distance D3 betweenthe second and third inner linings 110, 112 may be about 0.25 inches.

In some embodiments, the third inner lining has a substantiallyhourglass shape, with the front and rear portions of the third innerlining 112 being wider than a width of a central portion of the thirdinner lining. As with the above, the front portion of the third innerlining may be narrower than the rear portion. As will be appreciated,the shape and size of the third inner lining may vary based on the shapeand size of the crotch region of the outer shell.

As also shown in FIGS. 4-6 and 9-10, the third inner lining 112 may havea similar shape as the second inner lining 110. As will be appreciated,the third inner lining need not have the same shape as the second innerlining. For example, the third inner lining may have a substantiallyrectangular shape while the second inner lining has a substantiallyhourglass shape.

In some embodiments, the third inner lining 112 may include one or morelayers of material. For example, as shown in FIG. 12, in someembodiments, the third inner lining 112 may include first and secondlayers 118 a, 118 b. In some embodiments, the first and second layersmay be stitched to one another around a periphery of each layer. As willbe appreciated, although the third inner lining 112 is shown as havingtwo layers in this embodiment, the third inner lining also may have morethan two layers in other embodiments.

In some embodiments, a single inner lining may have a weight of betweenabout 3.7 oz./yd² to about 7.2 oz./yd². In some embodiments, a singleinner lining may have a weight of between about 7 oz./yd² to about 14.6oz./yd². In some embodiments, the combined weight of the inner linings(e.g., of the first, second and third inner linings) may be betweenabout 9.5 oz./yd² to about 24.9 oz/yd².

In embodiments in which an inner lining includes more than one layers,such as the third inner lining 112 having first and second layers 118 a,118 b (see FIG. 12), the combined weight of the layers may be the sameas the weight of a single layer. For example, the weight of the thirdinner lining with only a single layer, or the combined weight of a thirdinner lining having first and second layers, may be between about 3.7oz./yd² to about 7.2 oz./yd² or between about 7 oz./yd² to about 14.6oz./yd². In embodiments having more than one layers, the weight of eachlayer may be the same. For example, each of the first and second layersmay weigh about 2 oz./yd², with a combined weight of about 4 oz./yd².The weight of the individual layers also may be different. For example,a first layer may have a weight of about 1.5 oz./yd² and a second layermay have a weight of about 2.5 oz./yd², with a combined weight of about4 oz./yd².

FIGS. 13-19 illustrate the construction of a bodysuit according toembodiments of the present disclosure. As shown in FIG. 13, front andrear panels 106 a, 106 b of the first inner lining may be cut shorterthan the front and rear panels 102, 102 b of the outer shell. As withother embodiments, the front and rear panels 106 a, 106 b of the firstinner lining may be cut so that the front and rear panels 106 a 106 b donot extend to the crotch region 111 of the bodysuit. As shown in FIG.13, the crotch region 111 of the bodysuit may include a region that issubstantially hourglass in shape and that extends between the legs of awearer, adjacent a wearer's crotch.

As shown in FIG. 14, a second inner lining 110 may be cut in the generalshape of the crotch region of the outer shell so that it may be stitchedto the first inner lining and ultimately to the outer shell. As shown inFIG. 14, the second inner lining 110 may be attached to the front andrear panels 106 a, 106 b of the first inner lining at front and rearseams 108 a, 108 b. As will be appreciated, the first inner lining maybe stitched, bonded, welded or otherwise attached to the second innerlining at the front and rear seams 108 a, 108 b. In some embodiments,the second inner lining 110 may be flatlocked to the first inner lining106 a, 106 b at the front and rear seams 108 a, 108 b.

Next, as shown in FIG. 15, a third inner lining 112 may be cut forattachment to the second inner lining. In some embodiments, the thirdinner lining 112 may include a single layer. In other embodiments, twoor more layers may be cut and stitched together at the peripheral edgesto form the third inner lining 112. In some embodiments, the third innerlining is placed on top of and attached to the second inner lining 110.In some embodiments, the third inner lining 112 may be stitched to thesecond inner lining 110 at a front seam 114 a and rear seam 114 b. Forexample, the third inner lining 112 may be coverstitched to the secondinner lining at flatlock seam 114 a and at flatlock seam 114 b. As shownin these views, each of the flatlock seams extends generallyhorizontally across the third inner lining. In some embodiments, thethird inner lining is not yet attached to the second inner lining at oneor more side portions.

Although the seams 114 a, 114 b are described as being flatlocked, itwill be appreciated that the third inner lining 112 may be attached tothe second inner lining 110 via other suitable methods. For example, thethird inner lining may be welded, or otherwise bonded to the secondinner lining. Other suitable methods also may be used to join the secondand third inner linings.

FIGS. 16A and 16B show front and rear interior views of the bodysuitwith the first, second and third inner linings attached to one another.As also shown in this view, the front and rear panels 106 a, 106 b ofthe first inner lining have been stitched to the outer shell via sideseams 104.

FIGS. 17A and 17B illustrate construction of the leg opening bend back.As shown in these views, the leg opening bend back may be stitchedtogether via seam 120. During such construction, the second and thirdinner linings 110, 112 may be moved aside and out of the way.

Next, as shown in FIGS. 18A, and 18B, the second and third inner linings110, 112 may be stitched on top of the bend back at seam 122. As will beappreciated in view of FIGS. 18A and 18B, the second and third innerlinings 110, 112 may be attached to the bend back at respective sideportions of each inner lining.

In embodiments in which the third inner lining has more than one layer,the second inner lining may be secured in between the sub-layers of thethird lining, along the outer edge. The second inner lining may then besecured to the primary lining and to the outer shell

FIGS. 19A and 19B illustrate the attachment of the second and thirdinner linings 110, 112 to the leg opening bend back. As shown in theseviews, the second inner lining 110 is stitched on top of the bend back(see 126). The third inner lining 112 is stitched on top of the secondinner lining 110 and the bend back (see 128) to complete the threelayers of stitching in the leg opening of the crotch region.

FIG. 20 illustrates a side view of the linings in the crotch region ofthe bodysuit. As shown in this view, the crotch region 111 includes theouter shell 102 a of the leg opening bend back. As will be appreciated,the bend back stitching may come into contact with the skin. In thisregard, the bend back stitching may be covered by the second innerlining to prevent staining and wetness to the outer sell. In someembodiments, the second inner lining 110 comes into contact with theouter shell, as the second inner lining is placed in between the outershell and the third inner lining. The crotch region also may include thethird inner lining, which has a body-contacting side and is visible tothe wearer.

Although embodiments have been shown and described in which the firstinner lining extends to a crotch region, with the second inner liningbeing attached to the first inner lining and extending in the crotchregion, the bodysuit may have other arrangements in other embodiments.For example, the front panel of the first inner lining may extend from afirst position above a waist of the bodysuit to a second position abovethe crotch region and below the waist. In a similar fashion, the rearpanel of the first inner lining may extend from a third position above awaist of the bodysuit to a fourth position above the crotch region andbelow the waist. In such embodiments, the second inner lining may beattached to the front and rear panels at the second and fourth positionsabove the crotch region. In this regard, the second inner lining may beconnected to the first inner lining and extend from the second positionabove the front crotch region, through the crotch region, and to therear of the bodysuit to the fourth position above the rear crotchregion. In such embodiments, the second inner lining may be larger thanthe crotch region.

As will be appreciated, the inner linings may have any suitableproperties and be formed of any suitable materials. In some embodiments,the second inner lining may be formed of a stretchable material, such aslike nylon, cotton, thermoplastic urethane, spandex, polyester, lycra,elastane or a combination thereof. The second inner lining also may beformed of other similar stretchable materials. As will be described, thesecond inner lining may have unique properties that prevent moisturefrom leaking to the outer shell, is stain releasing, antibacterialand/or breathable. In some embodiments, the third inner lining may beformed of a stretchable materials like nylon, spandex, cotton,polyester, lycra, elastane, thermoplastic urethane, or combinationsthereof. The third layer also may be formed of other similar stretchablematerials. As will be described, the third lining may have uniqueproperties that are absorbent, breathable, wicking, or combinationsthereof. Although each of the first, second and third inner linings aredescribed as having certain properties, it will be appreciated thatthese linings may have other possible properties in other embodiments.

In some embodiments, the first, second and third inner linings may beconnected to one another via stitching, bonding, or welding, and using avariety of appropriate materials. In some embodiments, such aconstructions does not compromise the stretch properties of thebodysuit. Such a construction also may not negate the desired propertyor properties of the inner linings. For example, one or more of theinner linings may be wicking, absorbing, blocking, and/or releasing.

In some embodiments, suitable materials for one or more linings, such asa body-contacting lining, includes, but are not limited to: polyolefin,polyamide, polyester and combination thereof. In such embodiments, thematerials may have inherently stain-resisting fibers. For purposesherein, “stain releasing,” means both stain-resistant materials andstain-releasing materials, including those that have been treated to bestain resistant or stain releasing. The linings also may include anysuitable fabric that has been treated with a stain releasing finish(such as the Darlington finishes listed in Table A (see FIG. 21). Suchlinings also may include an inherently stain-releasing material such asmicrofiber or a microfiber blend including different materials that canbe treated to have even greater stain-releasing capabilities.

In some embodiments, one or more linings (e.g., the second or thirdinner linings) may be formed of a relatively dark material color thatcan assist in masking stains.

In some embodiments, one or more linings, such as the third innerlining, may include a material capable of absorbing fluids, and ofreleasing the absorbed fluids under certain conditions, such as during alaundry cycle. The moisture-absorbent lining may include an absorbencyof greater than about 300 grams/square meter (gm/m²), more particularlygreater than about 800 gm/m², and more particularly greater than about1054 gm/m². For example, in some embodiments, the third inner lining maybe capable of absorbing up to about 50 mL of fluid. Suitable materialsfor a moisture absorbent lining include, but are not limited to, wovenor non-woven microfiber or polymer knits, fabrics formed usinghydrophilic fibers, absorbent or superabsorbent foams, fibers orpowders. In some embodiments, any knit, absorbent knit, woven, nonwovenor polymeric material that has reservoir properties due to air gaps orvoids can be used as the moisture absorbing liner. Examples of suchmaterials include, but are not limited to, needlebar knit fabrics,foams, nonwovens, and the like.

In some embodiments, the moisture-absorbent lining can include a knittedfabric that has been treated to have hydrophilic properties. In someembodiments, the yarn from which the fabric is made can be treated priorto knitting to be hydrophilic. In some embodiments, the yarn and knittedfabric can both be treated to be hydrophilic.

In some embodiments, a barrier lining, such as the second inner lining,includes any material or combination of materials that prevent orminimize transmission of fluid through the barrier layer. In someembodiments, such a material or combination of materials does notadversely affect the feel and/or hand of the garment. In someembodiments, the barrier lining may include a woven or non-woven fabrichaving elongation test results comparable to the Darlington fabricslisted in Table A (see FIG. 21).

In some embodiments, the barrier lining may be formed of a materialincluding, but not limited to, a fabric laminated to a polymer film. Thepolymer film may comprise a thickness of less than or equal to about 15microns, more particularly less than or equal to about 10 microns, andmore particularly less than or equal to about 5 microns. Suitablematerials for the polymer film may include, but not be limited to,copolyether-esters, thermoplastic elastomers (TPEs) such as HYTREL®,nylons and polyolefins. Other soft elastic TPEs may be used if they havesufficient softness and pliability to be used in a bodysuit. The polyfilm may be laminated in a 2-ply or 3-ply configuration, or befree-hanging and sewn between other layers, such as between an absorbentlining and an outer layer. Other suitable polymer materials may includea highly moisture transmitting monolithic polyurethane film sold byOmniflex Inc., Greenfield, Mass. under the name TX1540.

Other suitable materials for the barrier lining may include, but are notlimited to, a 2-ply laminate polymer film protected by another layerthat is not bonded to the film, as this arrangement allows for a softerfeel in the finished garment. The film/composite material may optionallybe subjected to a hydrophobic (water-repellent) treatment to enhance thebarrier properties without negatively impacting the hand of thematerial. In still another embodiment, the barrier film or composite maybe stretched or pressed with heat and/or pressure into the surroundinglayers to enhance feel. These stretch or heat and pressure treatmentsalso have the advantage of creating small fissures that enhancebreathability.

Other suitable materials for barrier lining may include a hydrophobicfabric that may be inherently hydrophobic, or which may be treated tomake it hydrophobic. Suitable fabrics for treating with such hydrophobiccoatings include, but are not limited to, relatively tight knitted,nonwoven or woven fabrics. Suitable hydrophobic materials for treatingthe fabric include, but are not limited to, polymers such as silicone,polyurethane and combinations thereof. In many embodiments, it isdesirable to use elastic polymers for this purpose, such as LYCRA® andblends thereof. In some embodiments, the hydrophobic treated knitted,nonwoven or woven material may contain microfibers, as this creates amore tortuous path for any fluid to penetrate.

In some embodiments, if the material used to form the barrier layer isnonwoven, the use of a meltblown nonwoven material may be used, since italso provides a tortuous path for fluids. Multiple nonwoven, knitted orwoven materials may also be combined in any number of layers. Several orall layers may be treated with hydrophobic treatment or made ofinherently hydrophobic material(s). Embodiments using such treated(non-film) materials may provide greater breathability than may beachieved with a film barrier. One exemplary barrier layer is an elasticmeltblown nonwoven material made from a copolyether-ester polymersimilar to the product previously sold by Kimberly-Clark under the brandname DEMIQUE®.

In some embodiments, the barrier lining may include a microporouspolymer film. Suitable microporous polymer films may include, but arenot limited to, urethane films, polytetrafluoroethytene (PTFE) films,polyolefin films, and combinations thereof. One such microporousurethane film is sold by Porvair PLC, Norfolk, UK. Other microporousPIPE films are available under the product name GORE-TEX® (W. L. Gore &Associates, Inc., Newark, Del.). Such microporous films can be used inany combination of layers, either laminated or unlaminated, and can betreated with a hydrophobic water repellent treatment, or filled with asubstance such as oil, to keep the pores from becoming contaminated. Insome embodiments, the polymer film may be stretchable.

In some embodiments, a lining may include a single layer of fabric thathas a first surface that is stain resistant (inherently, or as a resultof being treated with a stain resistant treatment, as described above)and moisture-absorbent, and a second surface that is hydrophobic. Thefirst surface can be capable of absorbing an amount of fluid betweenabout 0.1 milliliters (“ml”) and about 50 ml of fluid within as littleas 95 cm² up to the entire surface area of the undergarment, and moreparticularly between about 3 ml and about 15 ml fluid. The second,opposite surface of the layer can be treated to be hydrophobic (asdescribed above) and to prevent or minimize the transmission of theabsorbed fluids. The second surface may be treated with a conventionaldurable water-repellent (DWR) treatment (such as ZEPEL® or othertreatments) and/or it may be saturated or impregnated with a hydrophobicpolymer (such as silicone or urethane). The hydrophobic polymer fillsthe gaps in the fabric, and may be applied by dip and squeeze, knifeover roll, spray, gravure, or other methods. The fabric used may be, forexample, a knit and with the stretch characteristics described above.The fabric may also include the use of microfiber.

In some embodiments, bonding of the seams may be done without stitchingusing tape or adhesive seams, or using sealants over the stitched seams.Suitable materials may include elastic polymer sealants and adhesives.Seams can also be sealed with seam tape such as Worthen Industries(Nashua, N.H.) Tape 375-4, using a Pfaff seam sealing machine.

In some embodiments, stitching of the seams may be done with thread thatis non-wicking. In some embodiments, the non-wicking thread may be usedto minimize fluid from wicking along the thread in stitched seams. Insome embodiments, the thread may be stretchable. The thread also mayhave other properties. For example, the thread may be hydrophilic ortreated to be hydrophilic. The thread also may be hydrophobic or treatedto be hydrophobic.

Although embodiments have been shown and described for a bodysuit, itwill be appreciated that the same inner lining construction may be usedin other garments. For example, the inner linings may be used in anundergarment. In such an example, the undergarment may include an outershell, a first inner lining that extends from the upper portion of theundergarment (e.g., a waist area of the undergarment) to a crotch seam.As with other embodiments, a second inner lining may extend from a frontcrotch seam to a rear crotch seam and be formed in the shape of thecrotch region. A third inner lining may be attached to a top of thesecond inner lining. The third inner lining may have the same shape asthe second inner lining but be smaller in size. The inner liningconstruction may be used in other garments in other embodiments. Forexample, the inner linings may be incorporated into a pair of pants(e.g., leggings).

While the present teachings have been described in conjunction withvarious embodiments and examples, it is not intended that the presentteachings be limited to such embodiments or examples. On the contrary,the present teachings encompass various alternatives, modifications, andequivalents, as will be appreciated by those of skill in the art.Accordingly, the foregoing description and drawings are by way ofexample only.

Various aspects of the present invention may be used alone, incombination, or in a variety of arrangements not specifically discussedin the embodiments described in the foregoing and is therefore notlimited in its application to the details and arrangement of componentsset forth in the foregoing description or illustrated in the drawings.For example, aspects described in one embodiment may be combined in anymanner with aspects described in other embodiments.

Also, the invention may be embodied as a method, of which an example hasbeen provided. The acts performed as part of the method may be orderedin any suitable way. Accordingly, embodiments may be constructed inwhich acts are performed in an order different than illustrated, whichmay include performing some acts simultaneously, even though shown assequential acts in illustrative embodiments.

Use of ordinal terms such as “first,” “second,” “third,” etc., in theclaims to modify a claim element does not by itself connote anypriority, precedence, or order of one claim element over another or thetemporal order in which acts of a method are performed, but are usedmerely as labels to distinguish one claim element having a certain namefrom another element having a same name (but for use of the ordinalterm) to distinguish the claim elements.

Also, the phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having,” “containing,” “involving,” andvariations thereof herein, is meant to encompass the items listedthereafter and equivalents thereof as well as additional items.

What is claimed is:
 1. A bodysuit comprising: an outer shell having afront panel and a rear panel; a first inner lining attached to the outershell, the first inner lining having a front panel and a rear panel, thefront panel of the first inner lining extending from above a waistlineof the outer shell front panel to a first seam and the rear panel of thefirst inner lining extending from above a waistline of the outer shellrear panel to a second seam, wherein the first seam is located at afirst side of a crotch region of the bodysuit and the second seam islocated at a second, opposite side of the crotch region of the bodysuit;and a second inner lining attached to the first inner lining at thefirst and second seams.
 2. The bodysuit of claim 1, wherein the firstand second seams are not joined to either of the front and rear panelsof the outer shell.
 3. The bodysuit of claim 1, wherein the first seamis located on a front side of the crotch region and the second seam islocated on a rear side of the crotch region.
 4. The bodysuit of claim 3,wherein the second inner lining extends rearwardly through the crotchregion from the first seam to the second seam.
 5. The bodysuit of claim1, further comprising a third lining positioned on an inner side of andattached to the second inner lining;
 6. The bodysuit of claim 1,wherein: the front panel of the first inner lining extends from aneckline of the front panel of the outer shell to the first seam; andthe rear panel of the first inner lining extends from a neckline of therear panel of the outer shell to the second seam.
 7. The bodysuit ofclaim 1, wherein a length of the front panel of the first inner liningis different than a length of the rear panel of the first inner lining.8. The bodysuit of claim 1, wherein the second inner lining has asubstantially hourglass shape.
 9. The bodysuit of claim 5, wherein thethird inner lining has a substantially hourglass shape.
 10. The bodysuitof claim 5, wherein the third inner lining is smaller than the secondinner lining.
 11. The bodysuit of claim 10, wherein: a front side of thethird inner lining is attached to a front side of the second innerlining at a third seam; and a rear side of the third inner lining isattached to a rear side of the second inner lining at a fourth seam. 12.The bodysuit of claim 11, wherein the third seam is adjacent to thefirst seam and the fourth seam is adjacent to the second seam.
 13. Thebodysuit of claim 11, wherein the third seam is longitudinally spacedfrom the first seam by a distance of at least about 0.25 inches.
 14. Thebodysuit of claim 13, wherein the second seam is longitudinally spacedfrom the fourth seam by a distance of at least about 0.25 inches. 15.The bodysuit of claim 10, wherein a first side of the third inner liningis spaced from a first side of the second inner lining by a distance ofat least about 0.125 inches.
 16. (canceled)
 17. (canceled)
 18. Thebodysuit of claim 1, wherein the second inner lining is a barrier layer.19. (canceled)
 20. The bodysuit of claim 5, wherein the third innerlining is formed of an absorbent material.
 21. The bodysuit of claim 20,wherein the third inner lining is arrange to absorb up to about 50 mL offluid.
 22. (canceled)
 23. The bodysuit of claim 1, wherein the frontpanel of the first inner lining is attached to the outer shell at afifth seam located on a first side of the bodysuit and at a sixth seamlocated on a second, opposite side of the bodysuit.
 24. A method ofconstructing a bodysuit having an outer shell with front and rearpanels; attaching a front panel of a first inner lining to a front panelof an outer shell of the bodysuit and attaching a rear panel of thefirst inner lining to a rear panel of the outer shell, wherein the frontpanel of the first inner lining extends from a portion above a waistlineof the outer shell to a first seam and the rear panel of the first innerlining extends from a portion above the waistline of the outer shell toa second seam, the first seam defining a first edge of a crotch regionof the bodysuit and the second seam defining a second edge of the crotchregion; and attaching a second inner lining to the front and rear panelsof the first inner lining at the first and second seams. 25.-28.(canceled)